Note: Descriptions are shown in the official language in which they were submitted.
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S P E C I F I C A T I O N
PROCESS FOR MAKING A DISPOSABLE DIAPER
TECHNICAL FIELD OF THE INVENTION
This invention relates to a disposable diaper.
BACKGROUND ART OF THE INVENTION
Japanese Utility Model Publication No. 1993-39531A
discloses a pants-type wearing article. In this wearing
article, tape fasteners folded in a Z-shape or an inverted
Z-shape so as to be unfolded in a waist-surrounding direction
when these tape fasteners are used are provided on a surface
of the rear waist region facing a garment the wearer puts on
in the vicinity of the rear waist region' s both side edges along
which the rear waist region is overlaid and joined together with
the front waist region. Top section of the tape fasteners
corresponding to the top of the Z=shape is coated on its under
surface with a self-adhesive. The tape fasteners may be
unfolded and anchored to the wearing article at its appropriate
positions to tighten the waist-surrounding dimension or to
retain the used diaper in a rolled up state.
The invention described in the above-cited Publication
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certainly provides a pants-type wearing article having tape
fasteners but not provides a process for making such a wearing
article. While it is obviously possible to attach tape
fasteners one by one to a wearing article, this invention aims
to attach tape fasteners to a wearing article, for example, a
disposable diaper in a remarkably efficient manner in the
process for continuously making the wearing article.
DISCLOSURE OF THE INVENTION
According to this invention, there is provided a process
for making a disposable diaper, the diaper having a surface
facing a wearer' s body and a surface facing a garment the wearer
puts on and contoured by front and rear ends extending in a
transverse direction and a pair of side edges extending in
parallel to each other in a longitudinal direction crossing the
transverse direction, the diaper being composed of, in the
longitudinal direction, a front waist region adjacent to the
front end, a rear waist region adj acent to the rear end and a
crotch region extending between these waist regions, and the
front or rear waist region of the surface facing a garment the
wearer puts on being provided in the vicinity of the side edges
with tape fasteners folded so that the tape fasteners are
unfolded in the transverse direction. This invention includes
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the steps of:
a ) feeding continuously a first web in the transverse direction
wherein the first web comprises a plurality of backsheets
defining the surface of the diaper destined to face a garment
the wearer puts on, having a pair of side edges and successively
connected one to another along the side edges so as to be
continuous in the transverse direction;
b) feeding tape fastener members to the first web fed in the
step a), wherein each of the tape fastener members extending
in the transverse direction has longitudinally opposite end
portions and an intermediate portion extending between the
opposite end portions, the opposite end portions being folded
in a Z-shape or an inverted Z-shape, top sections of the Z-shape
and the inverted Z-shape being coated on respective under
surfaces with a first self-adhesive and bottom sections of the
Z-shape and the inverted Z-shape being coated on respective
under surfaces with a second self-adhesive, and bonding the tape
fastener members by means of the second self-adhesive to the
surface destined to face a garment the wearer puts on in the
front or rear waist regions of the backsheets being contiguous
one to another along the side edges in the first web so that
the tape fastener members straddle the side edges,
respectively; and
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c) cutting the first web together with the tape fastener
members along the side edges.
This invention may be implemented also in manners as
follows:
( 1 ) The first web is fed in the step a) in the condition that
the first web is overlaid with a second web which is continuous
in the transverse direction and destined to be a topsheet
defining the surface facing the wearer's body and
liquid-absorbent cores arranged intermittently in the feeding
direction of these first and second webs between these first
and second webs.
( 2 ) The first web is destined to define the surface of an
open-type disposable diaper facing a garment the wearer puts
on.
( 3 ) The f first web is destined to be the backsheet def fining the
surface of a pants-type disposable diaper facing a garment the
wearer puts on and after the first web has been folded back along
a line bisecting a vertical dimension of the first web so that
a region of the first web destined to form the front waist regions
and a region of the first web destined to form the rear waist
regions are directly or indirectly overlaid each other, the
folded back two regions are joined together at zones each having
a desired width along lines to define the side edges of the diaper
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and thereafter the tape fastener members are bonded to the first
web by means of the second self-adhesive on both sides of the
respective zones of desired width so as to straddle the
respective zones.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a partially cutaway plan view showing a
disposable diaper;
Fig. 2 is a cross-sectional view taken along a line II
- II in Fig. 1;
Fig. 3 is a diagram illustrating a manner in which the
tape fasteners are used;
Fig. 4 is a diagram illustrating another manner in which
the tape fasteners are used;
Fig. 5 is a diagram illustrating a part of the process
for making a disposable diaper;
Fig. 6 is a cross-sectional view taken along a line VI
- VI in Fig. 5;
Fig. 7 is a cross-sectional view similar to Fig. 6
illustrating another embodiment of the tape fastener member;
Fig. 8 is a partially cutaway perspective view showing
a pants-type disposable diaper;
Fig. 9 is a cross-sectional view taken along a line IX
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- IX in Fig. 8;
Fig. 10 is a perspective view of a pants-type disposable
diaper illustrating a manner in which the tage fasteners are
used;
Fig. 11 is a diagram illustrating a part of the process
for making'a pants-type disposable diaper;
Fig. 12 is a cross-sectional view taken along a line XII
- XII in Fig. 11; and
Fig. 13 is a diagram similar to Fig. 11 illustrating a
part of the process for making a pants-type disposable diaper.
DESCRIPTION OF THE BEST MODE FOR WORKING OF THE INVENTION
Details of the process for making a disposable diaper
proposed by this invention will be more fully understood from
the description given hereunder with reference to the
accompanying drawings.
Fig. 1 is a partially cutaway plan view showing a
disposable diaper 1 made by the process according to this
invention and Fig. 2 is a cross-sectional view taken along a
line II - II in Fig . 1. The diaper 1 comprises a liquid-pervious
topsheet 2 facing a wearer's body, a liquid-impervious
backsheet 3 facing a garment the wearer puts on and a
liquid-absorbent core 4 interposed between these two sheets 2,
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3. Fig. 1 is the plan view showing the diaper 1 with the
backsheet 3 on the upper side and the topsheet 2 on the under
side. The diaper 1 is contoured by front and rear ends 11, 12
extending in parallel to each other in a transverse direction
and a pair of side edges 13 extending in parallel to each other
in a longitudinal direction orthogonal to the transverse
direction. The diaper 1 is composed of, in the longitudinal
' direction, a front waist region 6 put 'aside toward the front
end 11, a rear waist region 7 put aside toward the rear end 12
and a crotch region 8 extending between these two waist regions
6, 7. In the crotch region 8, the side edges 13 curve inward.
Respective portions of the top- and backsheets 2, 3 extend
outward beyond a peripheral edge of the core 4 and are overlaid
and joined together by means of a hot melt adhesive (not shown)
to form a front flap 16, a rear flap 17 and side flaps 18. In
the front f lap 16 and the rear f lap 17 , waist-surrounding
elastic members 19 are bonded in a stretched state to the inner
surface of at least one of the top- and backsheets 2, 3. In
the side flaps 18, thigh-surrounding elastic members 21 are
stretched along the curved side edges 13 and bonded in this
stretched state to the inner surface of at least one of the top-
and backsheets 2, 3. In the rear waist region 7, tape fasteners
are attached to the backsheet 3 in the vicinity of the
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respective side edges 13. The tape fasteners 30 are folded so
that these tape fasteners 30 may be unfolded outward beyond the
respective side edges 13.
As viewed in Fig. 2, each of the tage fasteners 30 consists
of a top tape section 31, a bottom tape section ~32 and an
intermediate tape section 33 lying between these top and bottom
tape sections 31, 32. The top tape section 31 has an inner end
portion 36, an outer end portion 37 and an intermediate portion
38 with respect to the diaper 1 and these portions 36 - 38 are
coated on the under surfaces thereof with the first
self-adhesive 39 . The bottom tape section 32 also has an inner
end portion 41, an outer end portion 42 and an intermediate
portion 43 and these portions 41 - 43 are coated on the under
surfaces thereof with the second self-adhesive 44. . Similarly,
the intermediate tape section 33 has an inner end portion 46,
an outer end portion 4? and an intermediate portion 48 and these
portions 46 - 48 are coated on the under surfaces thereof with
the third self-adhesive 49. The inner end portion 36 of the
top tape section 31 is temporarily fixed to an upper surface
32a of the bottom tape section 32 but firmly bonded to the folded
upward inner end portion 46 of the intermediate tape section
33. The outer end portion 37 of the top tape section 31 extends
outwardly of the diaper 1 beyond respective outer end portions
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of the bottom tape section 32 and the intermediate tape section
33. The first self-adhesive 39 coating the outer end portion
37 is covered with a small film strip 51. The intermediate
portion 38 of the top tape section 31 is temporarily fixed to
an upper surface 33a of the intermediate tape section 33. The
bottom tape section 32 is firmly bonded over its substantially
full length to an outer surface (upper surface as viewed in Fig.
2 ) of the backsheet 3 . The outer end portion 42 of the bottom
tape section 32 is folded upward and firmly bonded to the outer
end portion 47 of the intermediate tape section 33 by means of
the third self-adhesive 49. Except for the folded inner end
portion 46 bonded to the top tape section 31 and the outer end
portion 47 bonded to the outer end portion 42 of the bottom tape
section 32, the intermediate tape section 33, i.e., the
intermediate portion 48 thereof is temporarily fixed to the
upper surface 32a of the bottom tape section 32. The top tape
section 31, the intermediate tape section 33 and the bottom tape
section 32 arranged in this manner form the continuous tape
fastener folded in a Z-shape. The outer end portion 37 of the
top tape section 31 may be held together with the small film
strip 51 by f fingers and pulled in the direction P outwardly of
the diaper 1 to peel the temporarily fixed portions off one from
another and thereby to unfold the tape fastener 30 as indicated
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by imaginary lines. In order to facilitate the first
self-adhesive 39 to be peeled off from the bottom tape section
32 and the intermediate tape section 33 and/or in order to
facilitate the third self-adhesive 49 to be peeled off from the
bottom tape section 32, these tape sections 32, 33 may be coated
with a suitable release agent such as silicone oil.
Figs . 3 and 4 are diagrams illustrating manners in which
the tape fasteners 30 are used. Referring to Fig. 3, the tape
fasteners 30 are fully unfolded from the rear waist region 7
of the diaper 1 put on a wearer' s body and detachably. fixed to
the front waist region 6. Referring to Fig. 4, the used diaper
1 has been rolled up and retained by the tape fasteners 30 in
such a rolled up state. In this way, the tape fasteners 30 are
useful not only to put the diaper l on the wearer's body but
also to maintain the used diaper 1 in a rolled up state for
disposal thereof.
Fig. 5 is a diagram illustrating a part of the process
for continuously making the diapers 1. In a series of steps
( 1 ) - ( 3 ) illustrated in the lower part of this diagram, an arrow
pointing leftward indicates a machine direction MD. In the step
( 1 ) , a continuous diaper 65 is fed in the machine direction MD.
The continuous diaper 65 comprises continuous liquid-pervious
web 62 destined to define the topsheet 2 of the diaper 1,
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continuous liquid-impervious web 63 placed on the web 62 and
destined to define the backsheet 3 of the diaper 1 and the cores
4 intermittently arranged in the machine direction MD at given
intervals and interposed between these webs 62 , 63 . These webs
S 62, 63 are overlaid and joined together by means of a hot melt
adhesive (not shown) around the respective cores 4. Of the
continuous diaper 65, a dimension in a direction CD orthogonal
to the machine direction MD corresponds to a longitudinal
dimension of the individual diaper 1 and an imaginary line A
extending in the cross direction CD indicates a position
representing each of the side edges 13 of the individual diaper
1. In these two webs 62, 63, a plurality of topsheets 2 are
contiguous one to another along respective side edges 13 and
a plurality of backsheets 3 are contiguous one to another along
the respective side edges 13. The core 4 is placed between each
pair of the adj acent imaginary lines A, A and the overlaid webs
62, 63 are cut out approximately in the middle of the imaginary
line A to form a circular opening 66.
In the step ( 2 ) , the tape fastener members 67 are fed from
a series of steps (a) - (d) illustrated in the upper part of
the diagram and these tape fastener members 67 are attached to
the continuous diaper 65 traveling in the machine direction MD
so that these tape fastener members 67 may straddle the
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respective imaginary lines A.
In the step (3), the continuous diaper 65 is cut along
the imaginary lines A together with the taper fastener members
67 and the individual diapers 1 shown in Fig. 1 are obtained.
Peripheral edges of the openings 66 formed in the continuous
diaper 65 are destined to define the curved side edges 13 of
the diaper 1 in its crotch region 8.
. In a series of steps (a) - (d) illustrated in the upper
part of Fig. 5, the tape fastener members 67 are prepared. In
the step (a), continuous tape 367 destined to define the tape
fastener members 67 is fed from the right hand toward the left
hand as viewed in the diagram. In the step ( b ) , the continuous
tape 367 is cut in the transverse direction to obtain the
individual tape fastener members 67 . In the step ( c ) , the tape
fastener members 67 obtained in the step (b) are rotated by 90°
so that the members 67 may extend in the machine direction MD.
In the step (d) , the tape fastener members 67 rotated in this
manner are fed to the continuous diaper 65. It is possible to
feed the continuous tape 367 in the cross direction CD rather
than in the machine direction MD as illustrated and, in this
case, the individual tape fastener members 67 obtained by
cutting the continuous tape 367 are also fed in the cross
direction CD to the continuous diaper 65.
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Fig. 6 is a cross-sectional view of the continuous diaper
65 including the tape fastener members 67 shown in Fig. 5 as
taken along a line VI - VI in Fig. 5. The tape fastener member
67 is symmetric about the imaginary line A, so the left half
of the member 67 is not illustrated for the purpose of
simplification. The tape fastener member 67 comprises a first
tape section 131 straddling the imaginary line A and extending
in the machine direction MD, the bottom tape section 32 bonded
to the liquid-impervious web 63 on both sides of the imaginary
line A by means of the second self-adhesive 44 and the
intermediate tape section 33 temporarily fixed to the upper
surface 32a of the bottom tape section 32 by means of the third
self-adhesive 49. The first tape section 131 is temporarily
fixed to the upper surface of the intermediate tape section 33
by means of a self-adhesive 139 and this self-adhesive 139 is
covered with a small plastic film strip 151 in the vicinity of
the imaginary line A. These continuous diaper 65 and tape
fastener members 67 may be cut along the respective imaginary
lines A to obtain the individual diapers 1 and the tape fasteners
30 attached thereto as shown in Fig. 1 wherein the
liquid-pervious web 62 and the liquid-impervious web 63
respectively define the topsheet 2 and the backsheet 3. The
first tape section 131, the self-adhesive 139 and the small
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plastic film strip 151 in the tape fastener member 67 may be
cut along the imaginary line A to obtain the top tape section
31, the first self-adhesive 39 and the small plastic film strip
51 of the tape fastener 30 shown in Fig. 2. The bottom tape
S section 32 and the second self-adhesive 44 of the tape fastener
member 67 respectively define the bottom tape section 32 and
the second self-adhesive 44 of the diaper 1 and the intermediate
tape section 33 and the third self-adhesive 49 respectively
define the intermediate tape section 33 and the third
self-adhesive 49 of the diaper 1. Referring to Fig. 6, of two
tape fasteners 30 obtained from one and same tape fastener
member 67, the tape fastener 30 lying on the right side of the
imaginary line A - A is folded in a Z-shape and the tape fastener
30 lying on the left side 'is folded in an inverted Z-shape.
Such a process for continuously making the individual
diapers 1 characterized in that the continuous diaper 65 is cut
together with the tape fastener members 67 is more advantageous
than the process of well known art according to which the tape
fasteners 30 are separately prepared and attached to the diapers
1 one by one. The process according to this invention enables
steps of cutting base material for the tape fasteners 30 to be
eliminated by one step.
Fig. 7 is a diagram similar to Fig. 6 illustrating another
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embodiment of this invention. The tape fastener member 67 used
in this continuous diaper 65 comprises the top tape section 31,
the bottom tape section 32 and a second tape section 133
interposed between these two tape sections 31, 32 wherein the
second tape section 133 extends beyond the imaginary line A.
The tape fastener member 67 may be cut together with the
continuous diaper 65 along the imaginary line A to form the tape
fasteners 30 on both sides of the imaginary line A similarly
to the case of the tape fastener member 67 in Fig. 6. The top
tape section 31 in this tape fastener member 67 and the first
self-adhesive 39 applied on the under surface of this tape
section 31 function in the same manner as the top tape section
31 and the first self-adhesive 39 applied to the under surface
of this tape section 31 shown in Fig. 2 . The bottom tape section
32 in the tape fastener member 67 and the second self-adhesive
44 applied on the under surface of this section 32 function also
in the same manner of those in Fig. 2. While the second tape
section 133 and a self-adhesive 149 applied on the under surface
of the second tape section 133 function in the same manner as
the intermediate tape section 33 and the third self-adhesive
49 in Fig. 2, a portion 147 of the second tape section 133
extending beyond the outer end portion 42 of the bottom tape
section 32 to the imaginary line A is longer than the portion
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47 of the tape fastener 30 in Fig. 2 and firmly bonded to the
liquid-impervious web 63. In the diaper 1 using the second tape
section 133, the tape fastener 30 may be pulled leftward in the
direction P as viewed in Fig. 7 with the outer end portion 37
of the top tape section 3l held by fingers to unfold the top
tape section 31, the bottom tape section 32 and the second tape
section 133 in the same manner as the tape fastener 30 in Fig.
2. It should be understood that the portion 147 of the second
tape section 133 remains bonded to the backsheet 3 defined by
the second web 63. In the tape fastener 30 according to this
embodiment, the portion 147 bonded to the backsheet 3 over a
relatively large area is effective to prevent a force tending
to peel the bottom tape section 32 off from the backsheet 3 from
acting upon the bottom tape section 32.
Fig. 8 is a partially cutaway perspective view showing
a pants-type disposable diaper 201 made by the process according
to this invention. The diaper 201 comprises a liquid-pervious
topsheet 202, a liquid-impervious backsheet 203 and a
liquid-absorbent core 204 disposed between these two sheets 202,
203 so as to configure a front waist region 206, a rear waist
region 207 and a crotch region 208. The front and rear waist
regions 206, 207 are overlaid together in the vicinity of
transversely opposite side edges 213 thereof and joined
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together at bonding zones 210 arranged intermittently in the
longitudinal direction of the diaper 201 so as to define a
waist-hole 271 and a pair of leg-holes 272. Awaist-surrounding
elastic member 219 is attached in a stretched state to a
peripheral edge portion of the waist-hole 271 and
thigh-surrounding elastic members 221 are attached in a
stretched state to peripheral edge portions of the leg-holes
272 . The rear waist region 207 is provided with tape fasteners
230 in the vicinity of the respective side edges 213.
Fig. 9 is a cross-sectional view taken along a line IX
- IX in Fig. 8. In the diaper 201, the front and rear trunk
regions 206, 207 are overlaid together in the vicinity of the
side edges 213 and the top- and backsheets 202, 203 are joined
together at the bonding zones 210. The tape fastener 230 is
identical to the tape fastener 30 in Fig. 2, so the regions of
the tape fastener 230 are designated by the reference numerals
added 200 to the reference numerals of the corresponding tape
fastener 30. The tape fastener 230 can be unfolded with the
outer end portion 237 of the top tape section 231 held by fingers
so as to extend in the direction P beyond the side edge 213 of
the rear waist region 207 to the front waist region 206.
Fig. 10 is a perspective view of a pants-type disposable
diaper 201 illustrating a manner in which the tape fasteners
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230 are used. In the case of the diaper 201 shown in Fig. 10,
the front waist region 206 is pulled toward the rear waist region
207 using the tape fasteners 230 so that the diaper 201 may be
tucked to alleviate overabundance in the waist-surrounding
S direction. This tape fastener 230 also is useful to retain the
used diaper in a rolled up state as the tape fastener 30 of Fig.
is.
Fig. 11 is a diagram illustrating a part of the process
for continuously making the diaper 201 having the tape fasteners
230. In the step ( 1 ) , continuous diaper 265 destined to be the
pants-type diapers 201 is fed from the right hand toward the
left hand as viewed in Fig . 11, i . a . , in the machine direction
MD. The continuous diaper 265 is similar to the continuous
diaper 65 of Fig. 5 except that a continuous liquid-pervious
web 262 is placed on a continuous liquid-impervious web 263 and
the cores 204 are interposed between these webs 262, 263. In
the step (2), the continuous diaper 265 is folded back along
the center line C bisecting a dimension of the continuous diaper
265 in the cross direction CD crossing the machine direction
MD with the liquid-pervious web 262 inside. In the step ( 3 ) ,
the bonding zones 210 are formed on both sides of the imaginary
line A extending in the cross direction CD in the middle between
each pair of the adjacent cores 204, 204 so that two layers of
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the continuous diaper 265 formed by folding back may be
intermittently joined together. In the step (4), the tape
fastener members 267 are fed so as to straddle the bonding zones
210 in the machine direction MD and bonded to the
liquid-impervious web 263 on both sides of the bonding zones
210 . In the step ( 5 ) , the continuous diaper 265 is cut along
the imaginary lines A together with the tape fastener members
267 and the individual pants-type dialers 201 are obtained.
Fig. 12 is a cross-sectional view taken along a line XII
- XII in Fig. 11. On both sides of the respective imaginary
lines A extending across the continuous diaper 265, the
liquid-pervious web 262 and the liquid-impervious web 263
destined to form the front waist regions 206, on one hand, and
the liquid-pervious web 262 and the liquid-impervious web 263
destined to form the rear waist regions 207, on the other hand,
are welded together in the bonding zones 210. Similarly to the
tape fastener member 67 shown by Fig. 5, the tape fastener member
267 has the uppermost first tape section 131 straddling the
bonding zones 210 formed on both sides of the imaginary line
A. This tape fastener member 267 may be cut along the imaginary
line A to obtain the tape fastener 230 shown in Fig. 10.
Fig. 13 is a diagram similar to Fig. 11 illustrating a
part of the process for making the pants-type disposable diaper
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201 comprising steps different from those in the process
illustrated by Fig. 11. Referring to Fig. 13, in the step ( 3 ) ,
the tape fastener members 267 are fed to the continuous diaper
265 so as to straddle the respective imaginary lines A and bonded
to the liquid-impervious web 263 . In the step ( 4 ) , the bonding
zones 210 are formed on both sides of the respective imaginary
lines A. In the case that the liquid-pervious web 262 and the
liquid-impervious web 263 are made of a thermoplastic material
having a relatively low softening temperature such as
polyethylene or polypropylene and the tape fastener member 267
is made of a thermoplastic material having a relatively high
softening temperature such as polyester, the liquid-pervious
web 262 and the liquid-impervious web 263 may be heat-sealed
above the tage fastener member 267 to form the bonding zones
210 and thereby to obtain the pants-type diaper 201 having the
arrangement similar to that shown by Fig. 12.
It is possible without departing from the scope of this
invention to use, in the process illustrated by Figs. 11 and
13, the tape fastener member 67 shown in Fig. 6 instead of the
tape fastener member 267 shown in Fig. 12. In the process
illustrated by Fig. 11, it is possible without departing from
the scope of this invention to directly joined two layers of
the folded back liquid-impervious web263without interposition
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of the liquid-pervious web 262 in the bonding zones 210. The
liquid-pervious web 62, 262 and the liquid-impervious web 63,
263 are preferably made of a heat-sealable sheet material
containing thermoplastic synthetic resin over 50 wt$. This
invention may be implemented in a manner that the tape fasteners
30, 230 are attached to the front waist region 6, 206 instead
of attaching them to the rear waist region 7, 207 as for the
diaper 1, 201 as illustrated.
The process according to this invention for making the
disposable diapers is primarily characterized in that the
continuous diaper is cut together with the tape fastener members
and thereby the individual diapers are obtained. Thus the time
and labor required to prepare the tape fasteners for production
of the disposable diaper can be alleviated.
